Mopar R2853664AG Transfer Case

Converting a transfer case is a difficult task for the do-it-yourselfer as the transfer case entails a number of small parts, which have to be assembled and disassembled and the clearances that may need adjustment with spacer-select and snap-ring. While a competent do-it-yourselfer should be able to lift out and replace the transfer case, the actual overhaul is probably best left for a transmission shop because, being time-consuming and expensive, it rarely pays for itself unless the owner gets a hold of a remanufactured transfer case, which is a possibility through dealer parts and auto parts stores. As any other automotive repair, transfer case rebuilding can be easily accomplished by an inexperienced mechanic if they have the right special tools and do not rush and take their time to examine all possible details. Tools that would be useful for the job are internal and external snap-ring pliers, a bearing puller, a slide hammer, sets of pin punches, dial indicator, hydraulic press and may be a working bench and a vise or transmission stand. At this stage, it is important to write down the layout and connections of each piece since they will help at the time of reassembly. Knowledge of which part of the transfer case is not functioning as it should also assists in defining particular issues, the inspection and removal of parts becomes easier.

Before starting this procedure, shift the transfer case into Neutral. Disconnect the cable from the negative battery terminal, then raise the vehicle and support it securely on jackstands. Remove the skid plate if equipped, and drain the transfer case lubricant. Detach all vacuum/vent lines and electrical connectors from the transfer case, then disconnect the transfer case shift motor and sensor connectors. Remove the front and rear driveshafts, and on some models, it may be necessary to remove the rear crossmember. Support the transmission and transfer case with transmission jacks, securing the transfer case with safety chains. Remove the transfer case-to-transmission bolts/nuts, ensuring all wires and hoses are disconnected before moving the transfer case and jack toward the rear of the vehicle, keeping it level. Once the input shaft is clear, lower the transfer case and remove it from under the vehicle. For installation, remove all gasket material from the rear of the transmission, apply RTV sealant to both sides of the transfer-case-to-transmission gasket, and position it on the mating surface. With the transfer case secured to the jack, raise it into position behind the transmission and carefully slide it forward, engaging the input shaft with the transmission output shaft. Install the transfer case-to-transmission bolts/nuts, tightening them to the specified torque, then remove the safety chains and the jack supporting the transfer case. If removed, install the rear crossmember, then remove the transmission jack from under the transmission. Install the driveshafts, reattach all vacuum or vent lines, and plug in all electrical connectors. Connect the transfer case shift motor and sensor electrical connectors, refill the transfer case with lubricant, and if the vehicle has a manual transmission, check the lubricant level. Install the skid plate if equipped, remove the jackstands, lower the vehicle, connect the negative battery cable, and road test the vehicle for proper operation while checking for leakage.